Differential Case Replacement (195/218 mm Axles)

Differential Case Replacement (195/218mm Axles)

Special Tools

* DT 49909 - Axle Housing Spreader Adaptors

* J 8001 - Dial Indicator Set

* J 34178 - Spreader Gauge Adapter

* J 45222 - Axle Housing Spreader

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Remove the rear differential carrier cover. Refer to Rear Axle Housing Cover and Gasket Replacement (195/218mm) Rear Axle Housing Cover and Gasket Replacement (195/218 mm)Rear Axle Housing Cover and Gasket Replacement (250mm) Rear Axle Housing Cover and Gasket Replacement (250 mm).




2. Install the J 45222 - spreader and the DT 49909 - adapters (1).

3. Install the rear differential assembly in a vise.




4. Position the J 8001 - set (1) on the differential housing.

5. Using the J 45222 - spreader , spread the differential carrier just enough to remove the differential case assembly. DO NOT spread the differential carrier more than 1.02 mm (0.040 in)





Note: Mark the left and right bearing caps before removing them.

6. Remove the differential bearing caps (2) and the bolts (1).




7. Remove the differential case assembly (1) from the axle housing.

Installation Procedure

1. Lubricate the differential side bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations Fluids.




2. Install the differential case assembly (1).




3. Install the bearing caps (2) on the differential case.

Note: Do not torque the bearing cap bolts at this time. Hand tighten the bearing cap bolts.

4. Install the bearing caps bolts (1).

5. Adjust the differential side bearing preload. Refer to Drive Pinion and Ring Gear Replacement (195/218mm Axles) Drive Pinion and Ring Gear Replacement (195/218 mm Axles)Drive Pinion and Ring Gear Replacement (250mm Axle) Drive Pinion and Ring Gear Replacement (250 mm Axle).

6. Adjust the backlash. Refer to Backlash Adjustment (195/218mm) Backlash Adjustment (195/218 mm)Backlash Adjustment (250mm) Backlash Adjustment (250 mm).

7. Perform the gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection Gear Tooth Contact Pattern Inspection.

Caution: Refer to Fastener Caution Fastener Caution.

8. Tighten the bearing cap bolts (1).

* For vehicles with 195 mm axle, tighten to 63 Nm (46 lb ft).

* For vehicles with 218 mm axle, tighten to 105 Nm (77 lb ft).




9. Remove the J 45222 - fixture and the DT 49909 - adaptors (1).

10. Install the rear differential carrier cover. Refer to Rear Axle Housing Cover and Gasket Replacement (195/218mm) Rear Axle Housing Cover and Gasket Replacement (195/218 mm)Rear Axle Housing Cover and Gasket Replacement (250mm) Rear Axle Housing Cover and Gasket Replacement (250 mm).